Transmission Disassembly; Transmission Inspection - Honda XL200 2001 Shop Manual

CRANKSHAFT/TRANSMISSION
TRANSMISSION
DISASSEMBLY
Remove the shift fork shaft and remove the shift forks.
Remove the shift drum.
Remove the mainshaft and countershaft as an assembly from the
crankcase.
Disassemble the mainshaft and countershaft.
INSPECTION
Inspect each gear for wear or damage and replace if necessary.
Check the gear teeth and engagement dogs for wear or
damage.
Measure the I.D. of each spinning gear.
SERVICE LIMITS:
M3, M5, C4: 20.07 mm (0.790 in)
C1: 19.57 mm (0.770 in)
C2: 23.07 mm (0.908 in)
Measure the I.D. and O.D. of the gear bushings.
SERVICE LIMITS:
I.D.: C1: 16.55 mm (0.652 in)
C2: 20.05 mm (0.789 in)
O.D.: C1: 19.43 mm (0.765 in)
C2: 22.93 mm (0.903 in)
Check the mainshaft and countershaft splines and sliding
surfaces for wear or damage.
Measure the O.D. of the mainshaft and countershaft in the
locations as shown.
SERVICE LIMITS:
A (M3 gear): 19.91 mm (0.784 in)
B (C1 bushing): 16.41 mm (0.646 in)
C (C2 bushing): 19.92 mm (0.784 in)
D (C4 gear): 19.90 mm (0.783 in)
Calculate the gear-to-bushing clearance.
SERVICE LIMITS: 0.10 mm (0.004 in)
Calculate the bushing-to-shaft clearance.
SERVICE LIMITS: 0.08 mm (0.003 in)
1 0 -4
SHAFT
FORK
GEAR
MAINSHAFT
COUNTERSHAFT
XL2 0 0
DRUM
BUSHING